Cylinder Block Assembly: Service and Repair

Piston and cylinder bore dimensions








Fig. 1 Checking piston ring end gap
^ Insert ring at right angle from top and slide down until approximately 15 mm (19/32 inch) from lower edge of cylinder. To insert, use piston without rings.








Fig. 2 Checking piston ring side clearance
^ Before checking, clean ring groove.





Fig. 3 Checking piston diameter
^ Measure approximately 10 mm (3/8 inch) from bottom edge, at points offset by 90 from piston pin axis.
Deviation from nominal size: maximum 0.04 mm (0.0016 inch)





Fig. 4 Checking cylinder bore
Special tools and equipment
^ Inner bore gauge 50-100 mm (2-4 inch)

CAUTION: DO NOT have the cylinder block mounted to the assembly stand while measuring the cylinder bores. The block is deformed by its own weight under these conditions and this stress will result in false measurements that are not accurate after the tension has been relieved.

^ Measure at three locations diagonally in crosswise direction -A- and lengthwise direction -B-.
Deviation from nominal size: maximum 0.08 mm (0.0031 inch)